Flap-cushioning pressure relief assembly

Abstract

A pressure relief assembly includes a housing defining an air passage chamber having at least one airflow opening. A flap is secured within the air passage chamber. The flap is configured to move into an open position to expose the airflow opening(s) to relieve air pressure. A cushion is secured to the housing underneath the flap. The cushion is configured to cushion motion of the flap. A first attachment securely couples the flap to the housing. A second attachment securely couples the cushion to the housing. The first attachment is separate and distinct from the second attachment.

The invention claimed is: 
     
       1. A pressure relief assembly comprising:
 a housing defining a plurality of air passage chambers, wherein each of the air passage chambers have a plurality of airflow openings; 
 a plurality of flaps, wherein each of the plurality of flaps is secured within a respective one of the plurality of air passage chambers, wherein the plurality of flaps are configured to move into open positions to expose the plurality of airflow openings to relieve air pressure; 
 a plurality of cushions secured to the housing underneath the plurality of flaps, wherein the plurality of cushions are configured to cushion motion of the plurality of flaps; 
 a plurality of first attachments that securely couple the plurality of flaps to the housing; and 
 a plurality of second attachments that securely couple the plurality of cushions to the housing, wherein the plurality of first attachments are separate and distinct from the plurality of second attachments, 
 wherein the plurality of flaps are configured to sealingly engage the housing around the plurality of airflow openings without the plurality of cushions interfering with the plurality of flaps sealingly engaging the housing, 
 wherein at least one cushion of the plurality of cushions includes a plurality of clearance holes, and 
 wherein a plurality of protuberances extend outwardly from support ribs and extend through the plurality of clearance holes of the at least one cushion when the at least one cushion is seated on the support ribs, and wherein at least one of the plurality of protuberances is configured to abut an underside of the flap. 
 
     
     
       2. The pressure relief assembly of  claim 1 , wherein the plurality of first attachments are at a plurality of first locations of the housing, wherein the plurality of second attachments are at a plurality of second locations of the housing, and wherein the plurality of first locations differ from the plurality of second locations. 
     
     
       3. The pressure relief assembly of  claim 1 , wherein the plurality of first attachments are outside of the plurality of airflow openings, and wherein the plurality of second attachments extend into the plurality of airflow openings. 
     
     
       4. The pressure relief assembly of  claim 1 , wherein each of the plurality of flaps has a first size and a first shape, wherein each of the plurality of cushions has a second size and a second shape, and wherein the first size and the first shape differ from the second size and the second shape. 
     
     
       5. The pressure relief assembly of  claim 1 , wherein each of the plurality of flaps has a first peripheral envelope, wherein each of the plurality of cushions has a second peripheral envelope, and wherein the first peripheral envelope is greater than the second peripheral envelope. 
     
     
       6. The pressure relief assembly of  claim 1 , wherein each of the plurality of flaps is formed of a flexible thermoplastic elastomer, and wherein each of the plurality of cushions is formed of felt. 
     
     
       7. A pressure relief assembly comprising:
 a housing defining an air passage chamber having at least one airflow opening; 
 a flap formed of a flexible thermoplastic elastomer secured within the air passage chamber, wherein the flap is configured to move into an open position to expose the at least one airflow opening to relieve air pressure, wherein the flap has a first size and a first shape, wherein the flap has a first peripheral envelope; 
 a cushion formed of felt secured to the housing underneath the flap, wherein the cushion is configured to cushion motion of the flap, wherein the cushion has a second size and a second shape, wherein the first size and the first shape differ from the second size and the second shape, wherein the cushion has a second peripheral envelope, wherein the first peripheral envelope is greater than the second peripheral envelope, and wherein the cushion includes a plurality of tabs that extend outwardly from an upper edge of the cushion; 
 a first attachment comprising a connecting post at a first location of the housing that securely couples the flap to the housing, wherein the first attachment is outside of the at least one airflow opening; and 
 a second attachment comprising a hook dimensioned to engage one of the plurality of tabs at a second location of the housing that securely couples the cushion to the housing, wherein the first attachment is separate and distinct from the second attachment, wherein the first location differs from the second location, 
 wherein the second attachment extends into the at least one airflow opening, wherein the flap is configured to sealingly engage the housing around the at least one airflow opening without the cushion interfering with the flap sealingly engaging the housing. 
 
     
     
       8. The pressure relief assembly of  claim 7 , wherein the cushion comprises at least one clearance hole, wherein the housing comprises at least one protuberance extending outwardly from a support rib, wherein the at least one protuberance outwardly extends through the at least one clearance hole when the cushion is seated on the support rib, and wherein the at least one protuberance is configured to abut into an underside of the flap.